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Date:  11-30-2005
Number of Hours:  2.50
Manual Reference:  6-5
Brief Description:  Debur and countersink Rudder parts

Disassembled rudder and deburrred all parts. Spent some time trying to optimize the dimpling process to get best fit between nested dimples in .032 material. Compared two standard (squeezed) dimples; squeezing both sheets simultaneously; standard dimple on top and tank dimple on bottom, and finally, two standard dimples followed by squeezing again when nested together. Squeezing separately results in daylight between the sheets when held up to the light. Looks like the lower dimple should be deeper. Careful measurement indicated that squeezing dimples together resulted in a shallow lower dimple. It appears that the spring-back effect of the dies is lost on the lower dimple when both pieces are squeezed together. Suprisingly, the dimples didn't fit together exactly after squeezing together. I could see daylight between the sheets. Also found that using the tank die on the lower dimple left a rivet heat .010" below flush. Standard dies leave a rivet about .005" below flush. This difference is too much resulting in a little sideways slop when the two sheets are held together. Finally, I tried squeezing the dimples separately, and following up with a "nested" squeeze. This gave the best fit, and is what I will use going forward whenever the assembly sequence allows it. Dimpled all substructure parts as required. Countersunk back side of the rear spar doubler to fit dimpled #30 holes in rear spar per plans. Still waiting on getting the camera in the Mooney (45 min. drive to Sandy Valley!).
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